Laser-Welded Heating Component for Fast Temperature Sensing
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Solution Overview
Problem
Conventional heating systems for domestic appliances face challenges in compactness, cost-effectiveness, and rapid temperature response due to issues with temperature monitoring and control elements, such as slow response times caused by improper mounting and heat transfer inefficiencies.
Innovation Solution
A heating system component featuring a carrier unit and heating unit attached via laser welding, with a nonstick coating to prevent corrosion and improve heat transfer, and temperature monitoring units directly welded to the carrier unit for enhanced response time and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature monitoring and control elements are fixed with screws to a mounting plate that is soldered to the heating unit, then the mounting is mechanically secure, but the mounting plate curves and the response time becomes too slow
Solution Approach 1:
The temperature monitoring and control elements are directly integrated with the heating unit body, eliminating the separate mounting plate and screws. This merging of components creates direct thermal contact between the temperature elements and the heating unit, enabling rapid heat transfer while maintaining mechanical security through direct attachment.
Solution Approach 2:
The mounting plate and screws are removed from the system entirely. The temperature monitoring and control elements are attached directly to the heating unit body without requiring an intermediate mounting structure, thereby eliminating the sources of curvature and thermal resistance.
2Ease of manufacture
If the heating system uses conventional mounting methods with mounting plates and screws, then assembly is straightforward, but the system occupies more space and manufacturing complexity increases
Solution Approach 1:
The temperature monitoring and control elements are integrated directly into the heating unit body, combining multiple functions into a single structure. This eliminates the need for separate mounting plates, flanges, and fastening components, thereby reducing device complexity while maintaining ease of manufacture through direct attachment methods.
3Volume of moving object
If the heating system aims for compact construction, then space is reduced, but heat transfer efficiency to temperature monitoring elements deteriorates
Solution Approach 1:
The temperature monitoring and control elements are directly integrated with the heating unit body, creating direct thermal contact without intermediate structures. This merging enables efficient heat transfer within a compact configuration, as the temperature elements are in immediate proximity to the heat source without requiring additional space for mounting hardware.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a more compact, cost-effective heating system with improved heat transfer efficiency and rapid temperature response, reducing manufacturing complexities and ensuring reliable overheating protection.
Implementation Method 1
a heating unit (120) arranged on the dry side of the carrier unit (110)
Implementation Method 2
a heat transfer element which is arranged on the carrier unit (110) and comprises a material which is a good conductor of heat
Data Source
Figure 1~2
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AI summary
The present invention relates to a heating system component (100, 700, 900) for a heating system for heating a fluid medium, said heating system component (100, 700, 900) comprising: a carrier unit (110, 910) comprising a wet side, wherein said wet side corresponds to a surface of said carrier unit (110, 910) configured to be in contact with said fluid medium; a heating unit (120, 720, 920). The heating unit (120, 720, 920) may be coupled to the carrier unit (110, 910) by means of a coupling step, wherein said coupling step comprises at least one of a soldering step, a laser welding step, a gluing step, an ultrasonic welding step, and/or a friction welding step. The carrier unit (110, 910) may comprise aluminum.